Wood fibre based panel with a surface layer

Abstract

A building panel with a surface layer (1) including a wood veneer, a wood fibre based core (2) and a sub-layer (3) between the surface layer (1) and the core (2). The sub-layer (3) includes wood fibres (4) and a binder (5). The surface layer (1) has surface portions (6) including material from the sub-layer (3). The surface portions (6) including material from the sub-layer (3) extend into the wood veneer.

The invention claimed is: 
     
       1. A building panel comprising:
 a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions, 
 a wood fibre based core, and 
 a sub-layer arranged between the surface layer and the wood fibre based core, the sub-layer being a separate discrete layer from the core, 
 wherein the sub-layer comprises wood fibres and a binder, 
 wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and 
 wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the non-porous portions of the wood veneer in the compressed position so that the non-porous portions of the wood veneer form the protrusions. 
 
     
     
       2. The building panel as claimed in  claim 1 , wherein the surface portions comprising material from the sub-layer are flush with at least a portion of the surface layer. 
     
     
       3. The building panel as claimed in  claim 1 , wherein the sub-layer comprises colour pigments and/or a colorant. 
     
     
       4. The building panel as claimed in  claim 1 , wherein the sub-layer comprises wear resistant particles. 
     
     
       5. The building panel as claimed in  claim 1 , further comprising a powder-based balancing layer. 
     
     
       6. The building panel as claimed in  claim 1 , wherein the wood veneer comprises holes and/or cracks, wherein the sub-layer fills the holes and/or cracks of the wood veneer. 
     
     
       7. The building panel as claimed in  claim 1 , further comprising a protective overlay comprising wear resistant particles arranged on the surface layer. 
     
     
       8. The building panel as claimed in  claim 1 , wherein the binder is liquid. 
     
     
       9. The building panel as claimed in  claim 1 , wherein the binder in the sub-layer is a thermosetting resin. 
     
     
       10. The building panel as claimed in  claim 1 , wherein the binder in the sub-layer is a melamine formaldehyde resin. 
     
     
       11. The building panel as claimed in  claim 1 , wherein the sub-layer comprises a foaming agent. 
     
     
       12. The building panel as claimed in  claim 11 , wherein the foaming agent includes a chemical blowing agent additive. 
     
     
       13. The building panel as claimed in  claim 1 , further comprising:
 a second surface layer comprising a second wood veneer, the second surface layer being arranged on an opposite side of the core from the surface layer; and 
 a second sub-layer arranged between the second surface layer and the core, 
 wherein the second surface layer has surface portions comprising material from the second sub-layer extending into the second wood veneer. 
 
     
     
       14. A building panel comprising:
 a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions, 
 a wood fibre based core, and 
 a sub-layer arranged between the surface layer and the wood fibre based core, 
 wherein the sub-layer comprises wood fibres, a binder and colour pigments and/or a colorant, 
 wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and 
 wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the non-porous portions of the wood veneer form the protrusions by containing less of the binder than the porous portions. 
 
     
     
       15. The building panel as claimed in  claim 14 , further comprising a powder-based balancing layer. 
     
     
       16. The building panel as claimed in  claim 15 , further comprising a protective overlay comprising wear resistant particles arranged on the surface layer. 
     
     
       17. A building panel comprising:
 a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions, 
 a wood fibre based core, and 
 a sub-layer arranged between the surface layer and the wood fibre based core, 
 wherein the sub-layer comprises wood fibres, a binder and wear resistant particles, 
 wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, 
 wherein the binder is between 40-60 wt-% of the sub-layer, and 
 wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the non-porous portions of the wood veneer in the compressed position so that the non-porous portions of the wood veneer form the protrusions. 
 
     
     
       18. The building panel as claimed in  claim 17 , wherein the binder is liquid. 
     
     
       19. The building panel as claimed in  claim 17 , wherein the sub-layer comprises a foaming agent. 
     
     
       20. The building panel as claimed in  claim 17 , further comprising a powder-based balancing layer. 
     
     
       21. The building panel as claimed in  claim 20 , further comprising a protective overlay comprising wear resistant particles arranged on the surface layer. 
     
     
       22. A building panel comprising:
 a surface layer comprising a wood veneer, the wood veneer comprising relatively high-density portions and relatively low-density portions, 
 a wood fibre based core, and 
 a sub-layer arranged between the surface layer and the wood fibre based core, the sub-layer being a separate discrete layer from the core, 
 wherein the sub-layer comprises wood fibres and a binder, 
 wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and 
 wherein the surface layer comprises embossed portions and protrusions, wherein the binder of the sub-layer bonds the relatively low-density portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the relatively high-density portions of the wood veneer in the compressed position so that the relatively high-density portions of the wood veneer form the protrusions.